INVENTING SAFE PACKAGING FOR YOU

Transcription

1 INVENTING SAFE PACKAGING FOR YOU Raw Materials for Flexible Packaging: Fulfilling Your Specific Needs Covestro Deutschland AG Business Unit Coatings, Adhesives and Specialties D Leverkusen Germany This information and our technical advice whether verbal, in writing or by ways of trial are given in good faith but without warranty and are subject to change without notice. This also applies where proprietary rights of third parties are involved. The information is provided by Covestro AG without assumption of any liability. Our advice does not release you from the obligation to verify the information provided especially that contained in our safety data and technical information sheets, to check for updates of any information provided by us and to test our products as to their suitability for the intended processes and uses. The application, use and processing of our products and the products manufactured by you on the basis of our technical advice are beyond our control and, therefore, entirely your own responsibility. Our products are sold in accordance with the current version of our General Conditions of Sale and Delivery. Edition: 2015 Order-No.: COV Printed in Germany Bayhydur Desmodur Desmophen Dispercoll

2 02 Flexible Packaging Flexible Packaging 03 Contents Our Mission: INVENTING FOR YOU Where the market for flexible packaging is heading Building blocks for sustainable packaging and process efficiency Our technology the right answer to your needs An overview polyurethane adhesives by technology Our mission safe raw materials for safe packaging laminates A broad portfolio to suit your needs Fast-lane access to polyurethane innovations Bayhydur Desmodur Desmophen Dispercoll

3 04 Flexible Packaging Flexible Packaging 05 As your leading partner for polyurethane chemistry, we know you are competing in increasingly challenging environments: Your customers are becoming more and more demanding in their expectations for quality, durability, sustainability and aesthetics of products. And they have more choices. For you this means that cost pressure is rising while innovation cycles are becoming faster and faster. INVENTING VISIONS FOR YOU Helping you to turn this challenge into your competitive advantage is the goal that drives our daily work. We call it: INVENTING FOR YOU. But what exactly are the basic values underlying this promise? What principles enable us to improve your productivity, drive sustainability, ensure reliability and co-create future-proof businesses? First and foremost, we are curious. Because only if we listen closely to you and ask the right questions, we can respond to your individual needs with new, creative and unexpected solutions that make a real difference to you. That s why inventing for us always starts with thinking about your unmet business challenges. It requires an indepth understanding of your needs along the whole value chain. To make sure: What we invent stands the test of time. Living up to this aspiration requires more than competencies it calls for a corporate culture of being courageous. A culture that is defined and lived by dedicated people who cooperate to push the boundaries of invention founded on knowledge and experience. Our courage permeates our entire business from partnerships to business models. This is also reflected in our colorful business philosophy. We appreciate partnerships that go beyond traditional black-and-white ways of acting and thinking. An attitude of openness that invites you to co-create new things rather enabling you than just providing. We are optimistic and resourceful in finding solutions that inspire our customers and partners. This set of fundamental values adds up to an unrivaled performance orientation to constantly strive for the better, be it through big or small changes. A true sense of business regardless of function. And a deep commitment to delivering our promise everyday. Anywhere. Again and again. INVENTING FOR YOU.

4 06 Flexible Packaging Flexible Packaging 07 Where the market for flexible packaging is heading Social trends Flexible packaging is growing as a result of several lifestyle and other social trends. One of them is the trend towards more convenience. People like to buy products that are easy-to-open and reclosable for use on the go. This situationbased convenience trend underlines the growing importance of functional integration and new solutions such as reclosing, lightweight, and easy-opening packaging. Other lifestyle changes impacting on the industry include the increasing number of single households in developed countries, which is boosting the demand for more and smaller packaging sizes; the fast-growing market for pre-cooked meals in several regions of the world; and the need for flexible packaging to prolong shelf life and thus tackle the serious issue of food waste. Demand for greater sustainability The growth in flexible packaging is partly due to the fact that it is lighter than other packaging solutions like glass or metal, which makes it the more sustainable choice. This saves energy during transportation, which also makes it more cost-efficient. At the same time, the flexible packaging industry is constantly looking for solutions to make its packaging even more sustainable, i.e. through bio-based raw materials, even thinner materials, or recyclable solutions. Stricter food safety regulations Packaged food regulations are becoming stricter, with new regulations frequently issued. As a result, every member of the value chain from the raw material provider to the brand owner has to be extremely careful about ensuring the safety of their products. The question of which raw materials are used for which individual packed product has to be considered throughout the value chain. And that is why the industry is looking for economical products that simultaneously deliver a high degree of safety and avoid risk. Maximizing efficiency In a competitive environment it is crucial for converters to operate at the highest possible level of efficiency. That means high lamination speeds as well as the shortest possible productionto-customer times. Since ever-faster changes in packaging design are leading to smaller order sizes, converters need to adapt their production to this changing environment with a high degree of flexibility, while at the same time maintaining a high level of efficiency. Covestro is working on new product developments that will enable the flexible packaging industry to respond to these trends.

5 08 Flexible Packaging Flexible Packaging 09 Building blocks for sustainable packaging and process efficiency Solutions to enhance process efficiency Nowadays, the quality demands made on industry processes are very high. But at the same time, there is a clear need to cut costs. Both goals can be achieved by increasing process efficiency. The sheer complexity of the processes involved in manufacturing flexible packaging offers us various opportunities to enhance process efficiency. Significant process-optimizing and cost-cutting gains are possible, for example through faster curing and shorter process times. At Covestro we have a wide range of solutions designed to enhance your process efficiency. Why not take advantage of our know-how? These solutions will be beneficial for your bottom line. High performance enabled by nature Sustainability drives innovation at Covestro. We are committed to optimizing our manufacturing processes, reducing the impact of logistics, and enabling sustainability along the value chains. Renewable feedstocks offer opportunities for developing more sustainable building blocks for flexible packaging with significant potential for reducing the carbon footprint of end products while also reducing our overall dependence on fossil-based resources. But to make more sustainable solutions not just possible but also economically feasible, the performance of polyurethane adhesives, as the main technology for flexible packaging, needs to satisfy high industry standards. To this end, we are evaluating the use of renewable raw materials and will enlarge our product portfolio with new bio-based and mid- to long-term cost-competitive products, provided the raw materials become commercially available. In all these efforts we are committed to focusing on products that perform at least as well as established products but are at the same time more sustainable. Outstanding reliability, quality and supply security worldwide Covestro, the world s leading manufacturer of aliphatic and aromatic isocyanates, offers an extensive range of raw materials and services for manufacturers of flexible packaging. This allows the very latest technology to be used extremely effectively for a variety of applications. Thanks to its unique setup and worldwide network of state-of-the-art production sites, R&D facilities and customer technical centers, industry-leading supply chain setup, global orientation and local stocks, large and diversified product portfolio, highest health, safety and environmental (HSE) standards, as well as tailored supply chain flexibility with short lead times, Covestro offers the flexible packaging industry unrivaled supply security and assured quality.

6 10 Flexible Packaging Flexible Packaging 11 Our technology the right answer to your needs Polyurethane adhesives the main aromatic and aliphatic diisocyanates, pre-po- General-purpose laminates Medium-performance laminates High-performance laminates technology for flexible packaging lymers, aliphatic and aromatic crosslinkers for comprise film/film- or film/paper are used in fatty or acid food packag- are used for boil-in bag applications, Polyurethane (PU) adhesive polymers can be solvent-based adhesives, as well as difunctional composites and are typically used ing, temperature treatment up to hot fillings, sterilization processes produced from a wide range of raw materials. or polyfunctional polyether and polyester polyols. to pack dry food in room-tempera- pasteurization temperatures, and up to 134 C, pharmaceuticals, etc. The enormous adaptability of PU polymers allows The raw materials we provide are manufactured ture storage conditions. foil laminates. adhesive manufacturers to provide tailor-made in compliance with good manufacturing practice adhesive polymers for flexible packaging appli- and fulfill the requirements of Regulation (EC) cations. PU adhesives are therefore the number 1935/2004. one choice for producing film/film or film/foil The more demanding the application, the higher the degree of resistance Upon request, we can provide you laminates. PU adhesives are in use for all classes The requirements for adhesives differ from mar- required against chemical degradation and heat in the adhesive polymer, with a food contact use statement of laminates from general-purpose laminates for ket segment to market segment. Laminated film/ and the more food safety aspects that have to be taken into account. The for suitable adhesive raw materi- dry food up to high-performance laminates for film or film/foil composites are generally divided resistance of a poly urethane adhesive polymer can be significantly influ- als. Nevertheless, every adhesive steam sterilization processes at temperatures of into three quality clusters: general-purpose, enced by means of the polyurethane polymer building blocks, i.e. polyether manufacturer needs to make their up to 134 C and/or aggressive products. At medium-performance, and high-performance or polyester polyol, the crosslinking density, and the molecular weight of own assessment of compliance for PU adhesives are in use for steam sterilization processes at temperatures of up to Covestro we offer a broad range of raw materials for PU adhesives used for flexible packaging applications. Our product range comprises laminates. The filling, the filling process, and the final use of the product determine the type of raw material to be used. the adhesive polymer. Our raw materials for polyurethane adhesives can be used to produce single- and two-component solvent-based, solvent-free and water-based adhesives. each particular adhesive formulation and provide a declaration of compliance to downstream users, 134 C Safe adhesives for safe food Laminated films and foils for flexible packaging need to meet demanding i.e. converters and food manufacturers. and very specific requirements. This is particularly true when they are being used for food or in medical applications. A polymer used in food packaging applications in either direct or indirect food contact has to comply with various regulations depending on the region the flexible packaging lami- Technology lifecycle in flexible packaging Polyurethane adhesives nate is used in, for example: Commission Regulation (EU) No. 10/2011 BfR Recommendation XXVIII (Cross-linked polyurethanes as adhesive Solvent-free, aromatic Low monomer content Solvent-based Aromatic and aliphatic layers for food packaging materials FDA Regulations in 21 CFR (Adhesives) and 21 CFR (Laminate structures for use at temperatures o f 250 F and above) Chinese Hygienic Standard GB Growth Solvent-based, aliphatic Fast-curing (Desmodur quix 175) Solvent-free, aromatic High monomer content Water-based Very fast-curing (Desmodur XP 2802) Time

7 12 Flexible Packaging Flexible Packaging 13 An overview polyurethane adhesives by technology Solvent-based polyurethane Solvent-based polyurethane adhesives can be used as single-component NCO-terminated pre-polymers or as a combination of an OH-terminated polyurethane pre-polymer processed in combination with an isocyanate crosslinker (two-component solution). Since NCO-terminated pre-polymers require moisture to cure, they can only be used for laminates containing at least one moisture permeable substrate (e.g. paper). NCO-terminated pre-polymers are based on polyester and/or polyether polyols, which are chain-extended by monomeric diisocyanates. Typically we supply Desmodur 44M for this. The chain extension can be adjusted to the specific requirements with regard to the solid content, viscosity and adhesion properties of the adhesive polymer. Two-component solvent-based adhesives typically consist of an OH component and a solventbased crosslinker. The OH component itself usually is a pre-polymer based on polyester and/ or polyether polyols that are chain-extended with monomeric diisocyanates. The chain extension can be adjusted to the requirements with regard to the solid content, viscosity and adhesion properties of the adhesive polymer. Suitable solvent-based crosslinkers include Desmodur L 75, Desmodur UL-75 XP and Desmodur quix 175. The dosage of crosslinker depends on the OH content of the OH component. Typically the mol ratio of mol NCO : mol OH is in the range of Solvent-free polyurethane Solvent-free polyurethane adhesives can be used as one-component NCO-terminated pre-polymers or as two-component adhesives consisting of an OH component and an isocyanate component. Since one-component adhesives are NCO-terminated pre-polymers that need moisture to cure, the NCO pre-polymers can only be used for laminates containing at least one moisture permeable substrate (e.g. paper). NCO-terminated pre-polymers are usually based on polyester and/or polyether polyols that are chain-extended by monomeric diisocyanates (typically Desmodur 44M). The chain extension can be adjusted to suit the requirements with regard to viscosity and adhesion properties of the adhesive polymer. Two-component solvent-free adhesives typically consist of: An OH component ranging from low molecular weight polyfunctional polyols to chain-extended polyether / polyester polyols; the chain extension reaction is carried out with difunctional monomeric isocyanates. Plus an isocyanate component, comprising one or more NCO-terminated pre-polymers which are based on polyether / polyester polyols and monomeric isocyanate (e.g. Desmodur 44M); a low monomeric isocyanate content is an important aspect for product safety. Modern two-component solvent-free polyurethane adhesives therefore work with isocyanate components featuring low or ultra-low free monomeric isocyanate content. This improves food safety as well as making the converting process more economical. In addition, NCO-terminated pre-polymers with a low or ultra-low monomeric MDI content can be processed in combination with polyfunctional aliphatic isocyanates such as Desmodur N The co-use of Desmodur N 3600 helps to increase the functionality and the isocyanate content, reduce the viscosity of the two-component adhesive, and improve product safety.

8 14 Flexible Packaging Flexible Packaging 15 The polymer content of a polyurethane dispersion is typically in the range of % Water-based polyurethane Water-based polyurethane adhesives contain discrete droplets of polyurethane polymer. This is why even adhesive polymers of very high molecular weight can be applied as low-viscous adhesives. The polymer content is limited by the volume of polymer droplets in the dispersion. The polymer content of a polyurethane dispersion is typically in the % range. For two-component solvent-based and in particular solvent-free polyurethane adhesives, in contrast, the processing viscosity depends to a high degree on the molecular weight of the adhesive polymers. The higher the molecular weight, the higher the processing viscosity or, in the case of solvent-free adhesives, the higher the required application temperature has to be. Due to the lower molecular weight of their adhesive polymers, the initial bond strength of these adhesives is limited. Water-based adhesives overcome this barrier. Polyurethane dispersion adhesives permit the application of adhesive polymers with higher initial bond strength and thus allow a fast further processing of the laminate (slitting). Another important aspect is the fact that polyurethane adhesive dispersion polymers contain a much lower amount of low molecular weight constituents, which improves food safety even further by reducing the maximum migration from the adhesive polymer. Polyurethane dispersion adhesives can be used individually or in conjunction with a crosslinker. Two crosslinking technologies are available: Hydrophilic-modified aliphatic isocyanate (e.g. Bayhydur 3100) Polycarbodiimide dispersion (e.g. Desmodur XP 2802) The hydrophilic-modified aliphatic isocyanate is added to the polyurethane dispersion prior to use. The pot life of the two-component adhesive dispersion ranges from 3 to 6 hours depending on the type and amount of crosslinker used. A new and innovative crosslinking technology offered by Covestro is polycarbodiimide crosslinking (Desmodur XP 2802) for polyurethane dispersions. Desmodur XP 2802 enables the preparation of reactive one-component polyurethane dispersions that are storage-stable for up to six months, which makes processing very easy. Crosslinking is blocked as long as the system is still in dispersion state; the reaction of the adhesive polymer starts with the film formation of the adhesive layer, but, once it has started, it proceeds at very high speed.

9 16 Flexible Packaging Flexible Packaging 17 Our mission safe raw materials for safe packaging laminates Innovations for safe packaging and more efficient processes Modern PU adhesives for flexible packaging applications ideally combine three aspects: good processability, fast curing, and safety in both use and for consumers at the end of the value chain. The high reactivity of the adhesives enables converters to further process the laminate within a short period of time, which in turns allows laminates to be produced more economically. By using our PU raw materials adhesive manufacturers can offer their customers convincing answers to industry trends. PU ADHESIVE RAW MATERIAL CHARACTERISTIC FEATURE OPPORTUNITIES 2K solvent-based PU adhesive Desmodur quix 175 Highly reactive crosslinker with aliphatic bound NCO groups Crosslinker for solvent-based adhesives for high-performance laminates; fast curing at room temperature with no risk of aromatic amine formation Desmodur quix 175 complies with FDA : Laminate structures for use at temperatures of 250 F and above 1K reactive PU dispersion Desmodur XP 2802 Highly reactive polycarbodiimide crosslinker dispersion Crosslinker for water-based adhesives containing carboxyl groups in the polymer chain; fast curing after drying 2K solvent-based PU adhesive Desmodur UL 75 XP Aromatic crosslinker with ultra-low monomeric diisocyanate Crosslinker for solvent-based adhesives; low monomeric TDI content (< 0.1%) allows fast migrate-free laminates

10 18 Flexible Packaging Flexible Packaging 19 A broad portfolio to suit your needs Diisocyanates as building blocks for pre-polymers Diisocyanates, and in particular the MDI-grades, are used in combination with polyether or/and polyester polyols for manufacturing NCO-terminated pre-polymers. Desmodur T, Desmodur I and Desmodur H are usually used to extend the molecular weight of polyether or polyester diols in order to adjust the processing window and adhesion properties of the adhesive polymer. PAA migration Please note: When using MDI-based pre-polymers it is the converters /packagers responsibility to make sure that only laminates that display no monomeric MDI migration are used. The absence of MDI migration can be controlled by testing the primary aromatic amine (PAA). In conducting such tests, converters and packagers have to take into account the storage length and conditions of the packaged food for which the laminate is used (see Commission Regulation EU 10/2011). PRODUCT NCO CONTENT [%] PROPERTIES/ APPLICATIONS TYPE VISCOSITY [mpa s] Desmodur 44M, liquid 4,4 MDI C Chain extender; pre-polymers for solvent-free adhesives Desmodur LS 2424 MDI with high 2,4 - MDI isomer C Chain extender; pre-polymers for solvent-free adhesives with reduced viscosity or/and reduced monomer content Desmodur 2460 M MDI with high 2,4 -MDI isomer; color-stabilized C Chain extender; pre-polymers for solvent-free adhesives with reduced viscosity or/and reduced monomer content Desmodur T 100 Desmodur T 80 TDI with > 99.0 % 2,4-TDI TDI with 80.5 % 2,4-TDI C Chain extender C Chain extender Desmodur I IPDI C Chain extender Desmodur H HDI C Chain extender

11 20 Flexible Packaging Flexible Packaging 21 A broad portfolio to suit your needs NCO-terminated pre-polymers and polyfunctional isocyanates for solvent-free adhesives NCO-terminated pre-polymers are reaction products of aromatic or aliphatic isocyanates and polyols, such as polyethers or polyesters. Thanks to the wide variability of the isocyanate content and functionality, the viscosity of the pre-polymers and the mechanical properties of the finished products can be precisely adjusted. NCO-terminated pre-polymers can be used as the isocyanate components of 2K solvent-free adhesive. The pre-polymers can be used individually or in combination with other prepolymers, e.g. to adjust the processing viscosity or crosslinking density of the adhesive polymer. PRODUCT NCO CONTENT [%] 23 C [mpa s] TYPE MONOMERIC DIISOCYANATE PROPERTIES/ APPLICATIONS Desmodur E XP 2726 MDI pre-polymer 6.0 ca. 15 % 4,500 Pre-polymers for solvent-free adhesives Desmodur E 23 MDI pre-polymer 15.4 ca. 40 % 1,800 Pre-polymers for solvent-free adhesives Desmodur XP 2617 HDI pre-polymer % 4,250 Pre-polymers for solvent-free adhesives Desmodur N 3600 HDI trimer % 1,200 HDI isocyanurate Desmodur N 3300 HDI trimer % 3,000 HDI isocyanurate

12 22 Flexible Packaging Flexible Packaging 23 A broad portfolio to suit your needs Isocyanate crosslinkers for solvent-based adhesives Crosslinkers are used to crosslink solvent-based OH-terminated pre-polymers manufactured from polyether and/or polyester diols. The dosage of isocyanate crosslinker is usually in the range of isocyanate index All isocyanate crosslinkers except Desmodur N 3300 are dissolved in ethyl acetate. As an innovative product for flexible packaging, Desmodur quix 175 provides both aliphatic-bound isocyanate groups and high reactivity, which means a high degree of safety and efficiency for the converter. Solutions for water-borne adhesives Our water-based raw materials enable adhesive solutions that are both highly efficient and sustainable. Laminates made from water-based adhesives can be immediately processed and thus help to optimize and reduce costs in a converter s production process. Advantages of water-based adhesives in flexible packaging: Immediate slitting after lamination Very short post-curing time needed Quick response to customer requests Easy production handling thanks to 1K processing reactive adhesives Crosslinkers for water-based adhesives based on purely aliphatic raw materials Dispersions PRODUCT NCO CONTENT [%] PROPERTIES/ APPLICATIONS PRODUCT NON-VOLATILE CONTENT [%] PROPERTIES/ APPLICATIONS TYPE 23 C [mpa s] TYPE 23 C [mpa s] Desmodur L 75 Adduct of TDI/TMP 13 1,600 Standard crosslinker for solvent-based adhesives Dispercoll U XP 2643 Polyether-based PU dispersion < 1,000 Dispercoll polymer containing carboxyl groups in the polymer chain; can be crosslinked with isocyanate and polycarbodiimide Desmodur UL-75 XP Adduct of TDI/TMP ,600 Crosslinker for solvent-based adhesives with ultra-low monomeric TDI Dispercoll U 2824 XP Polyester-based PU dispersion Dispercoll polymer containing carboxyl groups in the polymer chain; can be crosslinked with isocyanate and polycarbodiimide Desmodur quix 175 Adduct of m-xdi/ TMP aliphatic isocyanate with reactivity of aromatic with TMP Crosslinker for solvent-based adhesives for high-performance laminates (FDA ) Dispercoll U 42 Dispercoll U XP 2682 Polyester-based PU dispersion Polyester-based PU dispersion < 1,000 Dispersion polymer can be crosslinked with isocyanate Dispersion polymer can be crosslinked with isocyanate Desmodur IL/EA TDI isocyanurate Desmodur HL/EA TDI/HDI isocyanurate ,100 Highly functional crosslinker for solvent-based adhesives Highly functional crosslinker with partly aliphatic NCO groups for solvent-based adhesives Crosslinkers PRODUCT VISCOSITY [mpa s] Desmodur N 3300 HDI isocyanurate ,000 Highly functional crosslinker with aliphatic NCO groups for solvent-based adhesives ACTIVE INGREDIENTS PROPERTIES/ APPLI- CATIONS Bayhydur % NCO Approx. 23 C Isocyanate crosslinker for water-based adhesives Desmodur XP 2802 Approx. 1 mmol/g N=C=N Approx. 30 Polycarbodiimide dispersion; crosslinker for carboxyl group containing water-based adhesive polymers

13 24 Flexible Packaging Flexible Packaging 25 A broad portfolio to suit your needs Polyether and polyester diols Polyester and polyester polyols can be used to produce both NCO- and OH-terminated pre-polymers for solvent-based or solvent-free one-component or two-component adhesives. Polyester polyols generally provide better adhesion to many substrates. Polyether polyols are used to reduce the processing viscosity and adjust the reactivity of the 2K polyurethane adhesives. Covestro offers a broad portfolio of polyester and polyether polyols that are suitable as building blocks for adhesives. The following table shows some selected examples. Please see also our brochure Resins Polyols and Aspartics for Reaction with Polyisocyanates for additional products. PRODUCT OH NUMBER [mg KOH/g] PROPERTIES/ APPLICATIONS TYPE VISCOSITY [mpa s] Baycoll AD 2047 Polyester diol Approx. 56 Approx. 75 C Hydrolysis resistance, slip agent compatibility Baycoll AD 2055 Polyester diol Approx. 56 Approx. 75 C Hydrolysis resistance, slip agent compatibility Baycoll CD 2084 Polyester diol Approx. 84 Approx. 75 C Compatibility Desmophen BD 2060 Polyether diol Approx. 56 Approx. 25 C Low viscosity, compatibility Desmophen BD 1110 Polyether diol Approx. 112 Approx. 25 C Low viscosity, compatibility Desmophen 1400 BT Polyether triol Approx. 400 Approx. 25 C Long pot life, short reaction time, compatibility, increase functionality

14 26 Flexible Packaging Flexible Packaging 27 Fast-lane access to polyurethane innovations At Covestro innovation is in our DNA. Ever since Otto Bayer discovered polyurethanes in 1937, we have been driving polyurethane innovations in coatings and adhesives as well as in other application areas. As our partner you enjoy fast-lane access to polyurethane innovations, and can help us in developing the next generation of polyurethanes to meet the industry s upcoming challenges and needs. What can we offer you? Powerful know-how on both established and new polyisocyanates, as well as on new poly urethane hybrid technologies. The prospect of new application technologies to enable efficient processes. More sustainable, biomass- or CO 2 -based materials that do not sacrifice high performance. Join us to shape the future!